Method of forming and using a lens holder

Abstract

A method of forming a lens holder comprising mounting a support member in a lens-holding body, forming at least one contact surface on the support member, positioning a former on the contact surface such that a curved surface defined by the former engages the contact surface, introducing a settable mass of flowable material into a cavity between the curved surface and the lens-holding body, and removing the former from the contact surface after the material has set. The set material defines a surface for supporting a lens having a curved surface substantially corresponding to the curved surface to the former. A plurality of support members may be formed by the method of the invention on a single lens holder.

We claim: 
     
       1. A method of forming a lens holder comprising mounting a support member on a lens-holding body, forming a curved contact surface on the support member, positioning a former on the curved contact surface so that a curved surface defined by the former seats on and generally follows the curvature of said curved contact surface, introducing a settable mass of flowable material into a cavity defined between said curved surface and the lens-holding body, and removing the former from the curved contact surface after the material has set whereby the set material and curved contact surface together define a permanent lens-supporting surface for a lens having a curved surface substantially corresponding to the curved surface of the former. 
     
     
       2. A method of forming a lens holder according to claim 1 comprising locating said support member in a socket in the lens-holding body. 
     
     
       3. A method of forming a lens holder according to claim 1 comprising providing a plurality of said support members on the lens-holding body to engage a toric surface on the former, the support member being arranged so as to engage the toric surface at positions which are symmetrical about the axis of the base curve of the toric surface. 
     
     
       4. A method of forming a lens holder according to claim 2 comprising providing a plurality of said support members on the lens-holding body to engage a toric surface on the former, the support member being arranged so as to engage the toric surface at positions which are symmetrical about the axis of the base curve of the toric surface. 
     
     
       5. A method of forming a lens holder according to claim 3 comprising providing four support members on the lens-holding body. 
     
     
       6. A method of forming a lens holder according to claim 1 wherein the support member is generally annular and extends around said cavity. 
     
     
       7. A method of forming a lens holder according to claim 2 wherein the support member is generally annular and extends around said cavity. 
     
     
       8. A method of forming a lens holder according to claim 6 wherein the periphery of the generally annualr support member is formed with an aperture or recess through which the flowable material is introduced into said cavity. 
     
     
       9. A method of forming a lens holder according to claim 1 comprising providing the surfaces of said set material with sealing means which sealingly engages said curved surface of the lens to be supported by the lens holder to enable the lens to be held in position by suction. 
     
     
       10. A method of forming a lens holder according to claim 9 wherein the sealing means is in the form of a sheet-like member which extends between said curved surface of the lens and the surface of the set material and which is formed with an aperture having edges which include radially inwardly directed lens supporting fingers and to which suction is to be applied to hold the lens in position in the holder. 
     
     
       11. A method of forming a lens holder according to claim 10 wherein the aperture communicates with a bore in the lens-holding body through which air is to be drawn to create said suction. 
     
     
       12. A method of forming a lens holder according to claim 1 wherein the former is a lens. 
     
     
       13. A method of forming a lens holder according to claim 1 wherein the settable mass of flowable material is a material introduced in a molten state. 
     
     
       14. A method of forming a lens holder according to claim 13 wherein the material is a low-melting point alloy. 
     
     
       15. A method of forming a lens holder, according to claim 14 wherein the material is an eutectic alloy of bismuth, indium, tin, lead and cadmium having a melting point in the region of 58° C. 
     
     
       16. A method of supporting a lens in a lens holder comprising mounting a support member on a lens-holding body, forming at least one curved contact surface on the support member, positioning a former on the curved contact surface so that a curved surface defined by the former seats on and generally follows the curvature of the curved contact surface, introducing a settable mass of flowable material into a cavity defined between said curved surface and the lens-holding body, removing the former from the curved contact surface after the material has set, and using the surface defined by the set material and said curved contact surface to support a lens having a curved surface substantially corresponding to the curved surface of the former. 
     
     
       17. A method of supporting a lens in a lens holder according to claim 16 comprising providing the surface of said set material with sealing means which sealingly engages said curved surface of the lens, and holding the lens in position by suction. 
     
     
       18. A method of supporting a lens in a lens holder according to claim 17 wherein the sealing means is in the form of a sheet-like member which extends between said curved surface of the lens and the surface of the set material and which is formed with an aperture having edges which include radially inwardly directed lens supporting fingers and to which suction is to be applied to hold the lens in position in the holder. 
     
     
       19. A method of supporting a lens in a lens holder according to claim 18 wherein the aperture communicates with a bore in the lens-holding body through which air is drawn to create said suction.